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Efficiency Filter FMEA

FMEA development is labor-intensive! Efficiency and effectiveness in preparation and execution are crucial for the acceptance of FMEA. Efficiency means analyzing the “right” scopes. Effectiveness means realizing the analysis in a targeted manner. The article provides hints on how to achieve these two goals.

Challenge / Task


FMEA ties up the working time of experts for product development and process planning. This target group is already a “bottleneck resource” for other reasons. Therefore, it is extremely important to handle the “deployment times” of these people carefully.

What and How?


It is important to develop the P FMEA from a clearly defined role. Different roles lead to differences in the content of the P FMEA. The prevailing role can be “plant operator”. Other conceivable roles could be, for example:
  1. Factory planner
  2. Plant developer
  3. Technical cleanliness officer
  4. and many more

What:

  • In the P FMEA, the roles of plant operators and developers are often mixed.
  • Systematic industrialization concepts are also analyzed.
  • Mixing these perspectives leads to erroneous P FMEA and unnecessary time expenditure.

How:
We recommend the use of efficiency filters for the preparation and execution of P FMEA.

This method helps to streamline the process and improve accuracy. It is explained below:

Fig. 1: Filter Application P FMEA (Source: Dietz Consultants GmbH)

The Method:

Fig. 2: Filter 0 (Source: Dietz Consultants GmbH)

Filter 0: Filter out overarching topics (e.g., safety, machine safety) to avoid double analyses.

Fig. 3: Filter 1 (Source: Dietz Consultants GmbH)

Filter 1: Identify value-adding processes and analyze them with P FMEA.

Fig. 4: Filter 2 (Source: Dietz Consultants GmbH)

Filter 2: Consider operating elements (e.g., maintenance) as apreventive controls in the P FMEA.

Fig. 5: Filter 3 (Source: Dietz Consultants GmbH)

Filter 3: Analyze device functions as potential failure causes in the value-adding FMEA.

Fig. 6: Filter 4 (Source: Dietz Consultants GmbH)

Filter 4: Analyze inspection processes as detection controls.

Fig. 7: Filter 5 (Source: Dietz Consultants GmbH)

Filter 5: Analyze integrated diagnostic and system reactions both as preventive and as detection controls in the P FMEA.